Expanding a tubular member

ABSTRACT

A tubular member is expanded by pressurizing an interior region within the tubular member.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. utility patent application Ser.No. 10/169,434, attorney docket no. 25791.10.04, filed on Feb. 18, 2003,which was the National Stage of PCT application Ser. No. PCT/US01/04753,attorney docket no. 25791.10.02, filed on Feb. 14, 2001, which claimedthe benefit of the filing date of U.S. provisional patent applicationNo. 60/183,546, attorney docket no. 25791.10, filed on Feb. 18, 2000,which was a continuation-in-part of U.S. Ser. No. 09/559,122, attorneydocket number 25791.23.02, filed on Apr. 26, 2000, which claimed thebenefit of the filing date of U.S. provisional patent application No.60/131,106, filed on Apr. 26, 1999, which was a continuation-in-part ofU.S. patent application Ser. No. 09/523,460, attorney docket number25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of thefiling date of U.S. provisional patent application No. 60/124,042, filedon Mar. 11, 1999, which was a continuation-in-part of U.S. patentapplication Ser. No. 09/510,913, attorney docket number 25791.7.02,which claimed the benefit of the filing date of U.S. provisional patentapplication No. 60/121,702, filed on Feb. 25, 1999, which was acontinuation-in-part of U.S. patent application Ser. No. 09/502,350,attorney docket number 25791.8.02, filed on Feb. 10, 2000, which claimedthe benefit of the filing date of U.S. provisional patent applicationNo. 60/119,611, attorney docket number 25791.8, filed on Feb. 11, 1999,which was a continuation-in-part of U.S. patent application Ser. No.09/454,139, attorney docket number 25791.3.02, filed on Dec. 3, 1999,which claimed the benefit of the filing date of U.S. provisional patentapplication No. 60/111,293, filed on Dec. 12, 7, 1998.

The present application is related to the following U.S. patentapplications: (1) utility patent application Ser. No. 09/440,338,attorney docket number 25791.9.02, filed on Nov. 15, 1999, which claimedthe benefit of the filing date of provisional patent application No.60/108,558, attorney docket number 25791.9, filed on Nov. 16, 1998; (2)utility patent application Ser. No. 09/454,139, attorney docket number25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of thefiling date of provisional patent application No. 60/111,293, attorneydocket number 25791.3, filed on Dec. 7, 1998; (3) utility patentapplication Ser. No. 09/502,350, attorney docket number 25791.8.02,filed on Feb. 10, 2000, which claimed the benefit of the filing date ofprovisional patent application No. 60/119,611, attorney docket number25791.8, filed on Feb. 11, 1999; (4) provisional patent application No.60/121 702, attorney docket number 25791.7, filed on Feb. 25, 1999; (5)provisional patent No. application No. 60/121,841, attorney docketnumber 25791.12, filed on Feb. 26, 1999; (6) provisional patentapplication No. 60/121,907, attorney docket number 25791.16, filed onFeb. 26, 1999; (7) provisional patent application No. 60/124,042,attorney docket number 25791.11, filed on Mar. 11, 1999; (8) provisionalpatent application No. 60/131,106, attorney docket number 25791.23,filed on Mar. 26, 1999; (9) provisional patent application No.60/137,998, attorney docket number 25791.17, filed on Jun. 7, 1999; (10)provisional patent application No. 60/143,039, attorney docket number25791.26, filed on Jul. 9, 1999; (11) provisional patent application No.60/146,203, attorney docket number 25791.25, filed on Jul. 29, 1999;(12) provisional patent application No. 60/154,047, attorney docketnumber 25791.29, filed on Sep. 16, 1999; (13) provisional patentapplication No. 60/159,082, attorney docket number 25791.34, filed onOct. 12, 1999; (14) provisional patent application No. 60/159,039,attorney docket number 25791.36, filed on Oct. 12, 1999; (13)provisional patent application No. 60/159,033, attorney docket number25791.37, filed on Oct. 12, 1999; (15) provisional patent applicationNo. 60/162,671, attorney docket number 25791.27, filed on Nov. 1, 1999,the disclosures of which are incorporated by reference.

BACKGROUND OF THE INVENTION

This invention relates generally to wellbore casings, and in particularto wellbore casings that are formed using expandable tubing.

The present invention is directed to overcoming one or more of thelimitations of the existing procedures for forming wellbores andwellheads.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a is a fragmentary cross-section illustration of an embodiment ofan apparatus and method for expanding tubular members.

FIG. 1 b is another fragmentary cross-sectional illustration of theapparatus of FIG. 1 a.

FIG. 1 c is another fragmentary cross-sectional illustration of theapparatus of FIG. 1 a.

FIG. 2 a is a fragmentary cross-section illustration of an embodiment ofan apparatus and method for expanding tubular members.

FIG. 2 b is another fragmentary cross-sectional illustration of theapparatus of FIG. 2 a.

FIG. 2 c is another fragmentary cross-sectional illustration of theapparatus of FIG. 2 a.

FIG. 2 d is another fragmentary cross-sectional illustration of theapparatus of FIG. 2 a.

FIG. 2 e is another fragmentary cross-sectional illustration of theapparatus of FIG. 2 a.

DETAILED DESCRIPTION OF THE ILLUSTRATION EMBODIMENTS

Referring now to FIGS. 1 a, 1 b and 1 c, an apparatus 100 for expandinga tubular member will be described. In a preferred embodiment, theapparatus 100 includes a support member 105, a packer 110, a firstfluidconduit 115, an annular fluid passage 120, fluid inlets 125, an annularseal 130, a second fluid conduit 135, a fluid passage 140, a mandrel145, a mandrel launcher 150, a tubular member 155, slips 160, and seals165. In a preferred embodiment, the apparatus 100 is used to radiallyexpand the tubular member 155. In this manner, the apparatus 100 may beused to form a wellbore casing, line a wellbore casing, form a pipeline,line a pipeline, form a structural support member, or repair a wellborecasing, pipeline or structural support member. In a preferredembodiment, the apparatus 100 is used to clad at least a portion of thetubular member 155 onto a preexisting tubular member. The support member105 is preferably coupled to the packer 110 and the mandrel launcher150. The support member 105 preferably is a tubular member fabricatedfrom any number of conventional commercially available materials suchas, for example, oilfield country tubular goods, low alloy steel, carbonsteel, or stainless steel. The support member 105 is preferably selectedto fit through a preexisting section of wellbore casing 170. In thismanner, the apparatus 100 may be positioned within the wellbore casing170. In a preferred embodiment, the support member 105 is releasablycoupled to the mandrel launcher 150. In this manner, the support member105 may be decoupled from the mandrel launcher 150 upon the completionof an extrusion operation.

The packer 110 is coupled to the support member 105 and the first fluidconduit 115. The packer 110 preferably provides a fluid seal between theoutside surface of the first fluid conduit 115 and the inside surface ofthe support member 105. In this manner, the packer 110 preferably sealsoff and, in combination with the support member 105, first fluid conduit115, second fluid conduit 135, and mandrel 145, defines an annularchamber 175. The packer 110 may be any number of conventionalcommercially available packers modified in accordance with the teachingsof the present disclosure. In a preferred embodiment, the packer 110 isan RTTS packer available from Halliburton Energy Services in order tooptimally provide high load and pressure containment capacity while alsoallowing the packer to be set and unset multiple times without having topull the packer out of the wellbore.

The first fluid conduit 115 is coupled to the packer 110 and the annularseal 130. The first fluid conduit 115 preferably is an annular memberfabricated from any number of conventional commercially availablematerials such as, for example, oilfield country tubular goods, lowalloy steel, carbon steel, or stainless steel. In a preferredembodiment, the first fluid conduit 115 includes one or more fluidinlets 125 for conveying fluidic materials from the annular fluidpassage 120 into the chamber 175.

The annular fluid passage 120 is defined by and positioned between theinterior surface of the first fluid conduit 115 and the interior surfaceof the second fluid conduit 135. The annular fluid passage 120 ispreferably adapted to convey fluidic materials such as cement, water,epoxy, lubricants, and slag mix at operating pressures and flow ratesranging from about 0 to 3,000 gallons/minute and 0 to 9,000 psi in orderto optimally provide flow rates and operational pressures for the radialexpansion process.

The fluid inlets 125 are positioned in an end portion of the first fluidconduit 115. The fluid inlets 125 preferably are adapted to conveyfluidic materials such as cement, water, epoxy, lubricants, and slag mixat operating pressures and flow rates ranging from about 0 to 9,000 psiand 0 to 3,000 gallons/minute in order to optimally provide flow ratesand operational pressures for the radial expansion process.

The annular seal 130 is coupled to the first fluid conduit 115 and thesecond fluid conduit 135. The annular seal 130 preferably provides afluid seat between the interior surface of the first fluid conduit 115and the exterior surface of the second fluid conduit 135. The annularseal 130 preferably provides a fluid seal between the interior surfaceof the first fluid conduit 115 and the exterior surface of the secondfluid conduit 135 during relative axial motion of the first fluidconduit 115 and the second fluid conduit 135. The annular seal 130 maybe any number of conventional commercially available seals such as, forexample, O-rings, polypak seals, or metal spring energized seals. In apreferred embodiment, the annular seal 130 is a polypak seal availablefrom Parker Seals.

The second fluid conduit 135 is coupled to the annular seal 130 and themandrel 145. The second fluid conduit preferably is a tubular memberfabricated from any number of conventional commercially availablematerials such as, for example, coiled tubing, oilfield country tubulargoods, low alloy steel, stainless steel, or low carbon steel. In apreferred embodiment, the second fluid conduit 135 is adapted to conveyfluidic materials such as cement, water, epoxy, lubricants, and slag mixat operating pressures and flow rates ranging from about 0 to 9,000 psiand 0 to 3,000 gallons/minute in order to optimally provide flow ratesand operational pressures for the radial expansion process.

The fluid passage 140 is coupled to the second fluid conduit 135 and themandrel 145. In a preferred embodiment, the fluid passage 140 is adaptedto convey fluidic materials such as cement, water, epoxy, lubricants,and slag mix at operating pressures and flow rates ranging from about 0to 9,000 psi and 0 to 3,000 gallons/minute in order to optimally provideflow rates and operational pressures for the radial expansion process.

The mandrel 145 is coupled to the second fluid conduit 135 and themandrel launcher 150. The mandrel 145 preferably are an annular memberhaving a conic section fabricated from any number of conventionalcommercially available materials such as, for example, machine toolsteel, ceramics, tungsten carbide, titanium or other high strengthalloys. In a preferred embodiment, the angle of the conic section of themandrel 145 ranges from about 0 to 30 degrees in order to optimallyexpand the mandrel launcher 150 and tubular member 155 in the radialdirection. In a preferred embodiment, the surface of the conic sectionranges from about 58 to 62 Rockwell C in order to optimally provide highyield strength. In a preferred embodiment, the expansion cone 145 isheat treated in order to optimally provide a hard outer surface and aresilient interior body in order to optimally provide abrasionresistance and fracture toughness. In an alternative embodiment, themandrel 145 is expandible in order to further optimally augment theradial expansion process.

The mandrel launcher 150 is coupled to the support member 105, themandrel 145, and the tubular member 155. The mandrel launcher 150preferably are a tubular member having a variable cross-section and areduced wall thickness in order to facilitate the radial expansionprocess. In a preferred embodiment, the cross-sectional area of themandrel launcher 150 at one end is adapted to mate with the mandrel 145,and at the other end, the cross-sectional area of the mandrel launcher150 is adapted to match the cross-sectional area of the tubular member155. In a preferred embodiment, the wall thickness of the mandrellauncher 150 ranges from about 50 to 100% of the wall thickness of thetubular member 155 in order to facilitate the initiation of the radialexpansion process,

The mandrel launcher 150 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low allow steel, stainless steel, orcarbon steel. In a preferred embodiment the mandrel launcher 150 isfabricated from oilfield country tubular goods having higher strengthbut lower wall thickness than the tubular member 155 in order tooptimally match the burst strength of the tubular member 155. In apreferred embodiment, the mandrel launcher 150 is removably coupled tothe tubular member 155. In this manner, the mandrel launcher 150 may beremoved from the wellbore 180 upon the completion of an extrusionoperation.

In an alternative embodiment, the support member 105 and the mandrellauncher 150 are integrally formed. In this alternative embodiment, thesupport member 105 preferably terminates above the top of the packer110. In this alternative embodiment, the fluid conduits 115 and/or 135provide structural support for the apparatus 100, using the packer 110to couple together the elements of the apparatus 100. In thisalternative embodiment, in a preferred embodiment, during the radialexpansion process, the packer 110 may be unset and reset, after theslips 160 have anchored the tubular member 155 to the previous casing170, within the tubular member 155, between radial expansion operations.In this manner, the packer 110 is moved downhole and the apparatus 100is re-stroked.

The tubular member 155 is coupled to the mandrel launcher, the slips 160and the seals 165. The tubular member 155 preferably is a tubular memberfabricated from any number of conventional commercially availablematerials such as, for example, low alloy steel, carbon steel, stainlesssteel, or oilfield country tubular goods. In a preferred embodiment, thetubular member 155 is fabricated from oilfield country tubular goods.

The slips 160 are coupled to the outside surface of the tubular member155. The slips 160 preferably are adapted to couple to the interiorwalls of a casing, pipeline or other structure upon the radial expansionof the tubular member 155. In this manner, the slips 160 providestructural support for the expanded tubular member 155. The slips 160may be any number of conventional commercially available slips such as,for example, RTTS packer tungsten carbide slips, RTTS packer wicker typemechanical slips or Model 3L retrievable bridge plug tungsten carbideupper mechanical slips. In a preferred embodiment, the slips 160 areRTTS packer tungsten carbide mechanical slips available from HalliburtonEnergy Services. In a preferred embodiment, the slips 160 are adapted tosupport axial forces ranging from about 0 to 750,000 lbf.

The seals 165 are coupled to the outside surface of the tubular member155. The seals 165 preferably provide a fluidic seal between the outsidesurface of the expanded tubular member 155 and the interior walls of acasing, pipeline or other structure upon the radial expansion of thetubular member 155. In this manner, the seals 165 provide a fluidic sealfor the expanded tubular member 155. The seals 165 may be any number ofconventional commercially available seals such as, for example, nitrilerubber, lead, Aflas rubber, Teflon, epoxy, or other elastomers. In apreferred embodiment, the seals 165 are rubber seals available fromnumerous commercial vendors in order to optimally provide pressuresealing and load bearing capacity.

During operation of the apparatus 100, the apparatus 100 is preferablylowered into a wellbore 180 having a preexisting section of wellborecasing 170. In a preferred embodiment, the apparatus 100 is positionedwith at least a portion of the tubular member 155 overlapping with aportion of the wellbore casing 170. In this manner, the radial expansionof the tubular member 155 will preferably cause the outside surface ofthe expanded tubular member 155 to couple with the inside surface of thewellbore casing 170. In a preferred embodiment, the radial expansion ofthe tubular member 155 will also cause the slips 160 and seals 165 toengage with the interior surface of the wellbore casing 170. In thismanner, the expanded tubular member 155 is provided with enhancedstructural support by the slips 160 and an enhanced fluid seal by theseals 165.

As illustrated in FIG. 1 b, after placement of the apparatus 100 in anoverlapping relationship with the wellbore casing 170, a fluidicmaterial 185 is preferably pumped into the chamber 175 using the fluidpassage 120 and the inlet passages 125. In a preferred embodiment, thefluidic material is pumped into the chamber 175 at operating pressuresand flow rates ranging from about 0 to 9,000 psi and 0 to 3,000gallons/minute in order to optimally provide flow rates and operationalpressures for the radial expansion process. The pumped fluidic material185 increase the operating pressure within the chamber 175. Theincreased operating pressure in the chamber 175 then causes the mandrel145 to extrude the mandrel launcher 150 and tubular member 155 off ofthe face of the mandrel 145. The extrusion of the mandrel launcher 150and tubular member 155 off of the face of the mandrel 145 causes themandrel launcher 150 and tubular member 155 to expand in the radialdirection. Continued pumping of the fluidic material 185 preferablycauses the entire length of the tubular member 155 to expand in theradial direction.

In a preferred embodiment, the pumping rate and pressure of the fluidicmaterial 185 is reduced during the latter stages of the extrusionprocess in order to minimize shock to the apparatus 100. In a preferredembodiment, the apparatus 100 includes shock absorbers for absorbing theshock caused by the completion of the extrusion process.

In a preferred embodiment, the extrusion process causes the mandrel 145to move in an axial direction 185. During the axial movement of themandrel, in a preferred embodiment, the fluid passage 140 conveysfluidic material 190 displaced by the moving mandrel 145 out of thewellbore 180. In this manner, the operational efficiency and speed ofthe extrusion process is enhanced.

In a preferred embodiment, the extrusion process includes the injectionof a hardenable fluidic material into the annular region between thetubular member 155 and the bore hole 180. In this manner, a hardenedsealing layer is provided between the expanded tubular member 155 andthe interior walls of the wellbore 180.

As illustrated in FIG. 1 c, in a preferred embodiment, upon thecompletion of the extrusion process, the support member 105, packer 110,first fluid conduit 115, annular seal 130, second fluid conduit 135,mandrel 145, and mandrel launcher 150 are moved from the wellbore 180.

In an alternative embodiment, the apparatus 100 is used to repair apreexisting wellbore casing or pipeline. In this alternative embodiment,both ends of the tubular member 155 preferably include slips 160 andseals 165.

In an alternative embodiment, the apparatus 100 is used to form atubular structural support for a building or offshore structure.

Referring now to FIGS. 2 a, 2 b, 2 c, 2 d, and 2 e, an apparatus 200 forexpanding a tubular member will be described. In a preferred embodiment,the apparatus 200 includes a support member 205, a mandrel launcher 210,a mandrel 215, a first fluid passage 220, a tubular member 225, slips230, seals 235, a shoe 240, and a second fluid passage 245. In apreferred embodiment, the apparatus 200 is used to radially expand themandrel launcher 210 and tubular member 225. In this manner, theapparatus 200 may be used to form a wellbore casing, line a wellborecasing, form a pipeline, line a pipeline, form a structural supportmember, or repair a wellbore casing, pipeline or structural supportmember. In a preferred embodiment, the apparatus 200 is used to clad atleast a portion of the tubular member 225 onto a preexisting structuralmember.

The support member 205 is preferably coupled to the mandrel launcher210. The support member 205 preferably is a tubular member fabricatedfrom any number of conventional commercially available materials suchas, for example, oilfield country tubular goods, low alloy steel, carbonsteel, or stainless steel. The support member 205, the mandrel launcher210, the tubular member 225, and the shoe 240 are preferably selected tofit through a preexisting section of wellbore casing 250. In thismanner, the apparatus 200 may be positioned within the wellbore casing270. In a preferred embodiment, the support member 205 is releasablycoupled to the mandrel launcher 210. In this manner, the support member205 may be decoupled from the mandrel launcher 210 upon the completionof an extrusion operation.

The mandrel launcher 210 is coupled to the support member 205 and thetubular member 225. The mandrel launcher 210 preferably are a tubularmember having a variable cross-section and a reduced wall thickness inorder to facilitate the radial expansion process. In a preferredembodiment, the cross-sectional area of the mandrel launcher 210 at oneend is adapted to mate with the mandrel 215, and at the other end, thecross-sectional area of the mandrel launcher 210 is adapted to match thecross-sectional area of the tubular member 225. In a preferredembodiment, the wall thickness of the mandrel launcher 210 ranges fromabout 50 to 100% of the wall thickness of the tubular member 225 inorder to facilitate the initiation of the radial expansion process.

The mandrel launcher 210 may be fabricated from any number ofconventional commercially available materials such as, for example,oilfield country tubular goods, low allow steel, stainless steel, orcarbon steel. In a preferred embodiment, the mandrel launcher 210 isfabricated from oilfield country tubular goods having higher strengthbut lower wall thickness than the tubular member 225 in order tooptimally match the burst strength of the tubular member 225. In apreferred embodiment, the mandrel launcher 210 is removably coupled tothe tubular member 225. In this manner, the mandrel launcher 210 may beremoved from the wellbore 260 upon the completion of an extrusionoperation.

The mandrel 215 is coupled to the mandrel launcher 210. The mandrel 215preferably are an annular member having a conic section fabricated fromany number of conventional commercially available materials such as, forexample, machine tool steel, ceramics, tungsten carbide, titanium orother high strength alloys. In a preferred embodiment, the angle of theconic section of the mandrel 215 ranges from about 0 to 30 degrees inorder to optimally expand the mandrel launcher 210 and the tubularmember 225 in the radial direction. In a preferred embodiment, thesurface of the conic section ranges from about 58 to 62 Rockwell C inorder to optimally provide high yield strength. In a preferredembodiment, the expansion cone 215 is heat treated in order to optimallyprovide a hard outer surface and a resilient interior body in order tooptimally provide abrasion resistance and fracture toughness. In analternative embodiment, the mandrel 215 is expandible in order tofurther optimally augment the radial expansion process.

The fluid passage 220 is positioned within the mandrel 215. The fluidpassage 220 is preferably adapted to convey fluidic materials such ascement, water, epoxy, lubricants, and slag mix at operating pressuresand flow rates ranging from about 0 to 9,000 psi and 0 to 3,000gallons/minute in order to optimally provide flow rates and operationalpressures for the radial expansion process. The fluid passage 220preferably includes an inlet 265 adapted to receive a plug, or othersimilar device. In this manner, the interior chamber 270 above themandrel 215 may be fluidicly isolated from the interior chamber 275below the mandrel 215.

The tubular member 225 is coupled to the mandrel launcher 210, the slips230 and the seals 235. The tubular member 225 preferably is a tubularmember fabricated from any number of conventional commercially availablematerials such as, for example, low alloy steel, carbon steel, stainlesssteel, or oilfield country tubular goods. In a preferred embodiment, thetubular member 225 is fabricated from oilfield country tubular goods.

The slips 230 are coupled to the outside surface of the tubular member225. The slips 230 preferably are adapted to couple to the interiorwalls of a casing, pipeline or other structure upon the radial expansionof the tubular member 225. In this manner, the slips 230 providestructural support for the expanded tubular member 225. The slips 230may be any number of conventional commercially available slips such as,for example, RTTS packer tungsten carbide mechanical slips, RTTS packerwicker type mechanical slips, or Model 3L retrievable bridge plugtungsten carbide upper mechanical slips. In a preferred embodiment, theslips 230 are adapted to support axial forces ranging from about 0 to750,000 lbf. The seals 235 are coupled to the outside surface of thetubular member 225. The seals 235 preferably provide a fluidic sealbetween the outside surface of the expanded tubular member 225 and theinterior walls of a casing, pipeline or other structure upon the radialexpansion of the tubular member 225. In this manner, the seals 235provide a fluidic seal for the expanded tubular member 225. The seals235 may be any number of conventional commercially available seals suchas, for example, nitrile rubber, lead, Aflas rubber, Teflon, epoxy orother elastomers. In a preferred embodiment, the seals 235 areconventional rubber seals available from various commercial vendors inorder to optimally provide pressure sealing and load bearing capacity.

The shoe 240 is coupled to the tubular member 225. The shoe 240preferably is a substantially tubular member having a fluid passage 245for conveying fluidic materials from the chamber 275 to the annularregion 270 outside of the apparatus 200. The shoe 240 may be any numberof conventional commercially available shoes such as, for example, aSuper Seal II float shoe, a Super Seal II Down-Jet float shoe, or aguide shoe with a sealing sleeve for a latch down plug modified inaccordance with the teachings of the present disclosure. In a preferredembodiment, the shoe 240 is an aluminum down-jet guide shoe with asealing sleeve for a latch down plug, available from Halliburton EnergyServices, modified in accordance with the teachings of the presentdisclosure, in order to optimally guide the tubular member 225 in thewellbore, optimally provide a fluidic seal between the interior andexterior diameters of the overlapping joint between the tubular members,and optimally facilitate the complete drilling out of the shoe and plugupon the completion of the cementing and radial expansion operations.

During operation of the apparatus 200, the apparatus 200 is preferablylowered into a wellbore 260 having a preexisting section of wellborecasing 275. In a preferred embodiment, the apparatus 200 is positionedwith at least a portion of the tubular member 225 overlapping with aportion of the wellbore casing 275. In this manner, the radial expansionof the tubular member 225 will preferably cause the outside surface ofthe expanded tubular member 225 to couple with the inside surface of thewellbore casing 275. In a preferred embodiment, the radial expansion ofthe tubular member 225 will also cause the slips 230 and seals 235 toengage with the interior surface of the wellbore casing 275. In thismanner, the expanded tubular member 225 is provided with enhancedstructural support by the slips 230 and an enhanced fluid seal by theseals 235.

As illustrated in FIG. 2 b, after placement of the apparatus 200 in anoverlapping relationship with the wellbore casing 275, a fluidicmaterial 280 is preferably pumped into the chamber 270. The fluidicmaterial 280 then passes through the fluid passage 220 into the chamber275. The fluidic material 280 then passes out of the chamber 275,through the fluid passage 245, and into the annular region 270. In apreferred embodiment, the fluidic material 280 is pumped into thechamber 270 at operating pressures and flow rates ranging from about 0to 9,000 psi and 0 to 3,000 gallons/minute in order to optimally provideflow rates and operational pressures for the radial expansion process.In a preferred embodiment, the fluidic material 280 is a hardenablefluidic sealing material in order to form a hardened outer annularmember around the expanded tubular member 225.

As illustrated in FIG. 2 c, at some later point in the process, a ball285, plug or other similar device, is introduced into the pumped fluidicmaterial 280. In a preferred embodiment, the ball 285 mates with andseals off the inlet 265 of the fluid passage 220. In this manner, thechamber 270 is fluidicly isolated from the chamber 275.

As illustrated in FIG. 2 d, after placement of the ball 285 in the inlet265 of the fluid passage 220, a fluidic material 290 is pumped into thechamber 270. The fluidic material is preferably pumped into the chamber270 at operating pressures and flow rates ranging from about 0 to 9,000psi and 0 to 3,000 gallons/minute in order to provide optimal operatingefficiency. The fluidic material 290 may be any number of conventionalcommercially available materials such as, for example, water, drillingmud, cement, epoxy, or slag mix. In a preferred embodiment, the fluidicmaterial 290 is a non-hardenable fluidic material in order to maximizeoperational efficiency.

Continued pumping of the fluidic material 290 increases fluidic material280 increases the operating pressure within the chamber 270. Theincreased operating pressure in the chamber 270 then causes the mandrel215 to extrude the mandrel launcher 210 and tubular member 225 off ofthe conical face of the mandrel 215. The extrusion of the mandrellauncher 210 and tubular member 225 off of the conical face of themandrel 215 causes the mandrel launcher 210 and tubular member 225 toexpand in the radial direction. Continued pumping of the fluidicmaterial 290 preferably causes the entire length of the tubular member225 to expand in the radial direction.

In a preferred embodiment, the pumping rate and pressure of the fluidicmaterial 290 is reduced during the latter stages of the extrusionprocess in order to minimize shock to the apparatus 200. In a preferredembodiment, the apparatus 200 includes shock absorbers for absorbing theshock caused by the completion of the extrusion process. In a preferredembodiment, the extrusion process causes the mandrel 215 to move in anaxial direction 295.

As illustrated in FIG. 2 e, in a preferred embodiment, upon thecompletion of the extrusion process, the support member 205, packer 210,first fluid conduit 215, annular seal 230, second fluid conduit 235,mandrel 245, and mandrel launcher 250 are removed from the wellbore 280,In a preferred embodiment, the resulting new section of wellbore casingincludes the preexisting wellbore casing 275, the expanded tubularmember 225, the slips 230, the seals 235, the shoe 240, and an outerannular layer 4000 of hardened fluidic material.

In an alternative embodiment, the apparatus 200 is used to repair apreexisting wellbore casing or pipeline. In this alternative embodiment,both ends of the tubular member 255 preferably include slips 260 andseals 265.

In an alternative embodiment, the apparatus 200 is used to form atubular structural support for a building or offshore structure.

In a preferred embodiment, the tubular members 105 and 225; shoes 240;expansion cone launchers 150 and 210; and expansion cones 145 and 215are provided substantially as described in one or more of the followingU.S. patent applications: (1) utility patent application Ser. No.09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999,which claimed the benefit of the filing date of provisional patentapplication No. 60/108,558, attorney docket number 25791.9, filed onNov. 16, 1998; (2) utility patent application Ser. No. 09/454,139,attorney docket number 25791.3.02, filed on Dec. 3, 1999, which claimedthe benefit of the filing date of provisional patent application No.60/111,293, attorney docket number 25791.3, filed on Dec. 7, 1998; (3)utility patent application Ser. No. 091502,350, attorney docket number25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of thefiling date of provisional patent application No. 60/119,611, attorneydocket number 25791.8, filed on Feb. 11, 1999; (4) provisional patentapplication No. 60/121,702, attorney docket number 25791.7, filed onFeb. 25, 1999; (5) provisional patent application No. 60/121,841,attorney docket number 25791.12, filed on Feb. 26, 1999; (6) provisionalpatent application No. 60/121,907, attorney docket number 25791.16,filed on Feb. 26, 1999; (7) provisional patent application No.60/124,042, attorney docket number 25791.11, filed on Mar. 11, 1999; (8)provisional patent application No. 60/131,106, attorney docket number25791.23, filed on Apr. 26, 1999; (9) provisional patent application No.60/137,998, attorney docket number 25791.17, filed on Jun. 7, 1999; (10)provisional patent application No. 60/143,039, attorney docket number25791.26, filed on Jul. 9, 1999; (11) provisional patent application No.60/146,203, attorney docket number 25791.25, filed on July 29, 1999;(12) provisional patent application No. 60/154,047, attorney docketnumber 25791.29, filed on Sept. 16, 1999; (13) provisional patentapplication No. 60/159,082, attorney docket number 25791.34, filed onOct. 12, 1999; (14) provisional patent application No. 60/159,039,attorney docket number 25791.36, filed on Oct. 12, 1999; (13)provisional patent application No. 60/159,033, attorney docket number25791.37, filed on Oct. 12, 1999; (15) provisional patent applicationNo. 60/162,671, attorney docket number 25791.27, filed on Nov. 1, 1999.Applicants incorporate by reference the disclosures of theseapplications.

Although illustrative embodiments of the invention have been shown anddescribed, a wide range of modification, changes and substitution iscontemplated in the foregoing disclosure. In some instances, somefeatures of the present invention may be employed without acorresponding use of the other features. Accordingly, it is appropriatethat the appended claims be construed broadly and in a manner consistentwith the scope of the invention.

1. An apparatus for radially expanding a tubular member, comprising: afirst tubular member; a second tubular member positioned within thefirst tubular member; a third tubular member movably coupled to andpositioned within the second tubular member; a first annular sealingmember for sealing an interface between the first and second tubularmembers; a second annular sealing member for sealing an interfacebetween the second and third tubular members; and a mandrel positionedwithin the first tubular member and coupled to an end of the thirdtubular member.
 2. The apparatus of claim 1, further including anannular chamber defined by the first tubular member, the second tubularmember, the third tubular member, the first annular sealing member, thesecond annular sealing member, and the mandrel.
 3. The apparatus ofclaim 1, further including an annular passage defined by the secondtubular member and the third tubular member.
 4. The apparatus of claim1, further including a fluid passage contained within the third tubularmember and the mandrel.
 5. The apparatus of claim 1, further includingone or more sealing members coupled to an exterior surface of the firsttubular member.
 6. The apparatus of claim 1, further including: anannular chamber defined by the first tubular member, the second tubularmember, the third tubular member, the first annular sealing member, thesecond annular sealing member, and the mandrel; and an annular passagedefined by the second tubular member and the third tubular member. 7.The apparatus of claim 6, wherein the annular chamber and the annularpassage are fluidicly coupled.
 8. The apparatus of claim 1, furtherincluding one or more slips coupled to the exterior surface of the firsttubular member.
 9. The apparatus of claim 1, wherein the mandrelincludes a conical surface.
 10. The apparatus of claim 9, wherein theangle of attack of the conical surface ranges from about 0 to 30degrees.
 11. The apparatus of claim 9, wherein the conical surface has asurface hardness ranging from about 58 to 62 Rockwell C.
 12. Anapparatus, comprising: a tubular member; a piston adapted to expand thediameter of the tubular member positioned within the tubular member, thepiston including a passage for conveying fluids out of the tubularmember; and an annular chamber defined by the piston and tubular member.13. The apparatus of claim 12, wherein the piston includes a conicalsurface.
 14. The apparatus of claim 13, wherein the angle of attack ofthe conical surface ranges from about 0 to 30 degrees.
 15. The apparatusof claim 14, wherein the conical surface has a surface hardness rangingfrom about 58 to 62 Rockwell C.
 16. The apparatus of claim 14, whereinthe tubular member includes one or more sealing members coupled to theexterior surface of the tubular member.
 17. An apparatus, comprising: afirst tubular member, and a second tubular member coupled to the firsttubular member by the process of: positioning the second tubular memberin an overlapping relationship to the first tubular member placing amandrel within the second tubular member; pressurizing an annular regionwithin the second tubular member above the mandrel; and displacing themandrel with respect to the second tubular member.
 18. The apparatus ofclaim 17, wherein the process for coupling the second tubular member tothe first tubular member further comprises: removing fluids within thesecond tubular member that are displaced by the displacement of themandrel.
 19. The apparatus of claim 18, wherein the removed fluids passinside the annular region.
 20. The apparatus of claim 17, wherein thevolume of the annular region increases.
 21. The apparatus of claim 17,wherein the process for coupling the second tubular member to the firsttubular member further comprises sealing off the annular region.
 22. Theapparatus of claim 31, wherein sealing off the annular region includessealing a stationary member and sealing a non-stationary member.
 23. Theapparatus of claim 17, wherein the process for coupling the secondtubular member to the first tubular member further comprises conveyingfluids in opposite directions.
 24. The apparatus of claim 17, whereinthe process for coupling the second tubular member to the first tubularmember further comprises conveying a pressurized fluid and anon-pressurized fluid in opposite directions.
 25. The apparatus of claim17, wherein the pressurizing is provided at operating pressures rangingfrom about 0 to 9,000 psi.
 26. The apparatus of claim 17, wherein thepressuring is provided at flow rates ranging from about 0 to 3,000gallons/minute.
 27. The apparatus of claim 17, wherein the first tubularmember includes a defective portion, and wherein the second tubularmember is positioned in opposing relation to the defective portion. 28.An apparatus for radially expanding a tubular member, comprising: afirst tubular member; a second tubular member coupled to the firsttubular member; a third tubular member coupled to the second tubularmember; and a mandrel positioned within the second tubular member andcoupled to an end portion of the third tubular member; wherein theinside diameter of the second tubular member is greater than the insidediameters of the first and third tubular members.
 29. The apparatus ofclaim 28, wherein the mandrel includes a fluid passage having an inletadapted to receive fluid stop member.
 30. The apparatus of claim 28,further including one or more slips coupled to the exterior surface ofthe third tubular member.
 31. The apparatus of claim 28, wherein themandrel includes a conical surface.
 32. The apparatus of claim 31,wherein the angle of attack of the conical surface ranges from about 0to 30 degrees.
 33. The apparatus of claim 31, wherein the conicalsurface has a surface hardness ranging from about 58 to 62 Rockwell C.34. An apparatus, comprising: a tubular member having a first portion, asecond portion, and a third portion; and a piston adapted to expand thediameter of the tubular member positioned within the second portion ofthe tubular member, the piston including a passage for conveying fluidsout of the tubular member; wherein the inside diameter of the secondportion of the tubular member is greater than the inside diameters ofthe first and third portions of the tubular member.
 35. The apparatus ofclaim 34, wherein the piston includes a conical surface.
 36. Theapparatus of claim 35, wherein the angle of attack of the conicalsurface ranges from about 0 to 30 degrees.
 37. The apparatus of claim35, wherein the conical surface has a surface hardness ranging fromabout 58 to 62 Rockwell C.
 38. The apparatus of claim 34, wherein thetubular member includes one or more sealing members coupled to theexterior surface of the tubular member.
 39. An apparatus for radiallyexpanding a tubular member, comprising: a first tubular member; a secondtubular member positioned within the first tubular member; a thirdtubular member movably coupled to and positioned within the secondtubular member; a first annular sealing member for sealing an interfacebetween the first and second tubular members; a second annular sealingmember for sealing an interface between the second and third tubularmembers; a mandrel positioned within the first tubular member andcoupled to an end of the third tubular member; an annular chamberdefined by the first tubular member, the second tubular member, thethird tubular member, the first annular sealing member, the secondannular sealing member, and the mandrel; a fluid passage defined by thethird tubular member and the mandrel fluidicly coupled to an interiorregion of the first tubular member below the mandrel; and an annularpassage defined by the second tubular member and the third tubularmember fluidicly coupled to the annular chamber.
 40. An apparatus,comprising: a first tubular member; and a second tubular member coupledto the first tubular member by the process of: positioning the secondtubular member in an overlapping relationship to the first tubularmember; placing a mandrel within the second tubular member; sealing offan annular region within the second tubular member above the mandrel bysealing a stationary member and sealing a non-stationary member;pressurizing the annular region; displacing the mandrel with respect tothe second tubular member; and removing fluids within the second tubularmember that are displaced by the displacement of the mandrel by passingthe removed fluids inside of the annular region.
 41. An apparatus forradially expanding a tubular member, comprising: a first tubular member;a second tubular member coupled to the first tubular member; a thirdtubular member coupled to the second tubular member; one or more slipscoupled to the exterior surface of the third tubular member; and amandrel having a conical outer surface including an angle of attackbetween about 0 to 30 degrees and a surface hardness ranging from about58 to 62 Rockwell C positioned within the second tubular member andcoupled to an end portion of the third tubular member; wherein theinside diameter of the second tubular member is greater than the insidediameters of the first and third tubular members; wherein the mandrelincludes a fluid passage having an inlet adapted to receive fluid stopmember.